Refractory liner material



Patented Dec. 5, 1950 ol -Fi es REFRACTORY LINER Mam 1mm DayidMyerj Canton, and:

Dov r; Ohio; assignors w n r-Banjer we Unit; 'mcar eratea; DoverlOhio; eofp'dration uf ohio in Drawin Apfil ieation; Serial No. ,6

gmber 23, 1 948 75Glaifiis; (CL-110622611);

The im'rerititn relates b a heat resisting re: fractory composition 'niatrial; and more" artiul'a'i'lyto a" porous refractorwlirier' composition for rurnace andboi'nb ustion chambers: burner tube's, biirner blocks; internal combustion en gifieii'ianifolds;' and the" like: The invention elfibhdi's'" improvements" over the invention dis ci's'd in the prior c'o pendin application of s'aid 'David Meyer, Serial No; 686,950, filed July 29,.19'46, and entitled FuelBiirrier-Liner.

Refractory linings -for burner tubes and-combastion chambers for melting forging and heat treating furnaces must be capable elf-withstandmg.- extremely severe conditions. Such linings mustresistvery high temperatures without substantial deterioration; yet-should havehigh heat insulating properties, facilitate combustio-mandimprove the efficiency of the fuel being: burned. Prior: refractory linings which are'zhig h in heat insulatingfiquality arep'oroiis and quick to deteriorate; and those-that have a-relatively long life are substantially non porous and hence -relatively 'p'oor heatxinsulators.

m burne'rs the refractory 'lin-ingishou-ld be of flfi pdi'bilS and absorbent nature so as to: romote u substantially complete oombustizi aiid' preterit fiisiori properties and highheat resisting? dergo substantial shrinkage which results" erapkirigg sfiallifig, or otherwise breakin down. Other diffi'eiilties which arise in cennction with usingetliese clays for a linermaterial include the liner material which will withstand extremely mgfi "temperatures" aria rapid temperature" qhii-ng's" without substantially deteriorating or breaking ddWIil centund'e1-nign teiriperatiiresafidrad ate annex-- iiiiunf amount of" Heat without deterioration;

A" nlrther'ebject is to provide a noveire'rram wry" iner material which has the property" or 5 ilitatifig co'iiiiiletecornbus'tidfi o'f tlie'fuel mix nee within" the'liiieri b er ob 'e'ct' "is to" provide-a never refractory mate" lowing description may'fie attained by tlie'cnovi composition cemprisingjthe present invention the which s set for'th Iin' t'lie'jfollb itig; desoription and definedii'ri the amended:claims :rerniinea1jart hereof-I The nature oi tiie novel refractory liner material may-he stated-Yin general-terms as ifielud 'f-usion'non-shrinking basie clays and a binder.

to whi'eh'mixture isadded a zsmallflproportion of a-dry mixture of: plasterof ,Paris,-= alum peras -abi-nder, although other suitable binder ma-- terial, sueh as dolomite; may be substituted for Sagger clay. Missouri clay and Bolivar' clay areburnedafter being mined and then crushed to approximatelwpeav'size; The Sagger-clay is used in=the-npla3stie coriditionas' mined and-is not burned. fIhie three' 'basic' clays are mixed 'thor onghly in -"these proportions" .byifirst shredding the sagger= of-Bancelay-"in' its plastic form and mixing the shreds with the crushed lflint' clays; Water mayi'ibe adde'd'vtothemlxtiire to" make "thei'noisture scontent about 5%.; wh-ieh renders the mixture plastic; and :the plastic: mass 1 may he p egge'diintol'blok fofhf foi oilveniehtihan l eryamixtu l whibhisihighly resistantat High tlie-ohem-ieals is-preparedln I" shersnawmgzprbpwionez Parts Plaster of Paris 16 Powdered alum 1 Permanganate of potash 1 Salicylic acid 1 In order to thoroughly mix the dry mixture of chemicals with the clay mixture, the clay mass may be broken up into shreds and a small quantity of the dry mixture of chemicals sprinkled over the shreds. A quantity of the mixture of clay and chemicals is then rammed or pressed into a form, which may be a burner housing absorbing atomized liquid fuel particles dis- I chargedinto the tube from the usual burner tip,

around a removable core, or the mixed mass may be rammed between a form and a furnace or combustion chamber wall by means of a pneumatic hammer. The principal function of the plaster of Paris is to form a protective coating around the other chemicals, because otherwise violent reactions are apt to take place between certain impurities in the clay and the otherchemicals. Accordingly, other chemical powders which will form this coating may be used in place of the plaster of Paris.

In the case of forming a liner tube for a burner, alternate layers of the mixed clays and powdered chemical mixture may be rammed within the burner housing until a complete liner has been formed,.as described in said application'serial No.

686,950. In preparing the refractory liner material for application to the walls of a combustion chamber or heating furnace, the dry mixture of chemicals which, is sprinkled over the shreds of clay mixture is used in the approximate proportions of two gallons of powdered chemicals to about one ton of the finished mixture of clay and chemicals. Two gallons of a dry mixture of the chemicals in the proportions given weighs approximately sixteen pounds.

.Although we prefer to use a mixture of Missouri clay and Bolivar clay with Sagger or Ball clay, we can use a mixture of Bolivar clay and Sagger or Ball clay or equivalent binder material without any Missouri clay. In such case, however, it is necessary to add some crushed'firebrick to oifset the shrinkage of the clay, because even though it has been burned, the Bolivar clay has a greater tendency towards shrinkage under high temperatures than does the Missouri clay. As

cordingly, when the Missouri clay is omitted, we

prefer to use about 70% pre-burned crushed Boli var flint clay with'about 10% of crushed firebrick and about of Sagger or Ball clay. This mixture may beramrned or pressed within the burner housing or the like with alternate layers of the dry chemic'al'mixture' as described in said application Serial No. 686,950, or it may be wetted and formed into a' plastic mass which'is shredded and mixed by sprinkling the dry chemical mixture the'reover, and then rammed into a form'by a pneumatic'hammer and the like, as previously described herein. I

Either of the clay mixtures with the chemical mixture may,'if desired, be pressed into uniform size plastic blocks or bricks by the use of a portable forming machine, and these plastic blocks may be laidup to provide a furnace or combustion chamber lining. Such blocks need not be dried or burned, but when laid up and thelaying surface is'wetted they become plastic and adhere.

It is to be understood that the proportions of the clays or the clays and firebrick, as well as thej'proportions of the chemical mixture which is. added, are approximate and may be varied somewhat to produce liner. material to suit dif:

.stan'ds high temperatures within the furnace.

'and the absorbed particles become instantane- 15' ously gasified to facilitate complete combustion of the fuel with a characteristic incandescent flame and no carbon deposition. Burners equipped with the improved liner composition will light instantaneously when cold without pre-heating, apparently because of the charge of fuel retained within the porous structure'of the liner after-previous use has been discontinued.

It has been found in actual practice that a com--. bustion chamber lined with the improved refractory lining requires less fuel to maintain a free} quired degree of temperature, apparently because of the substantially complete combustion which is facilitated by thepresence of the porous refractory lining, and at the same time the actual life of the novel lining has been found to be consid erably longer than that of prior refractory linings used under the-same conditions. Moreover, "the improved refractory lining will withstand rapid temperature changes without substantial deterioration, and is extremely resistant to the acid fumes generated in heating or melting furnaces by the oxidation of the metals being heated therein. 7

In actual practice, we have found that the" improved liner material withstands temperatures. of the order of 4,000 F. without substantial deteri-,- oration, and at such temperatures the liner be comes incandescent. and promotes substantially complete combustion and maximum efiiciency Moreover, the improved refractory liner material has very high heat in sulating properties. a

The reasons for all the advantages attained from the use of the novel refractory liner material in burner tubes, combustion chambers and the like, and the functions of all of the ingredients present in the material, are not fully understood, It may be that the action of the liner composition or some of the ingredients thereof is in part catalytic. However, the porous and absorbent character of the liner material, together withits high heat resisting and heat insulating properties; enables the attainment of substantially complete combustion with increased effioiency and minimum deterioration of the-liner material. The novel refractory liner material provides a porous, heat insulating composition which with and temperature changes with-a minimum amount of deterioration. I t is suitable for lining burner tubes, and a variety of furnace and combustion chamber walls. It promotes complete combustion and greater fuel efiiciency. I

In the foregoing description, certain terms have been usedfor brevity, understanding and clarity, but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such words are utilized for descrip' tive. purposes herein and not for the purpose of limitation. j m I. J

Having now described the features of the invention, and the composition of a preferred embodiment of novel refractory liner material; and having described the new and useful results attained and the problems solved; the novel and advantageous composition, together with reasonable equivalents obvious to those skilled in the art,-is set forth in the appended claims.

We claim:

1. A porous refractory liner composition consisting of a body of non-shrinking high fusion basic flint clay and binder material, said body containing a small quantity of a mixture of equal parts of powdered alum, permanganate of potash and salicylic acid and sixteen parts of plaster of Paris, the ratio of the mixture to the total composition being approximately sixteen pounds to the ton.

2. A porous refractory liner composition consisting of a body of non-shrinking high fusion basic flint clay and a binder selected from the class consisting of Sagger clay, Ball clay, and dolomite, said body containing a small quantity of a mixture of equal parts of powdered alum,

permanganate of potash and salicylic acid and sixteen parts of plaster of Paris, the ratio of the mixture to the total composition being approximately sixteen pounds to the ton.

3. A porous refractory liner composition consisting of a body of about 80% to 83% of nonshrinking high fusion basic flint clay with about 20% to 17% of binder material, said body containing a small quantity of a mixture of equal parts of powdered alum, permanganate of potash and salicylic acid and sixteen parts of plaster of Paris, the ratio of the mixture to the total composition being approximately sixteen pounds to the ton.

4. A porous refractory liner composition consisting of a body of about 80% to 83% of nonshrinking high fusion basic flint clay with about 20% to 17% of a binder selected from the class consisting of Sagger clay, Ball clay, and dolomite, said body containing a small quantity of a mixture of equal parts of powdered alum, permanganate of potash and salicylic acid and sixteen 6 I parts of plaster of Paris, the ratio of the mixtur to the total composition being approximately sixteen pounds to the ton.

5. A porous refractory liner composition consisting of a body containing about 80% preburned and crushed Missouri flint clay, about 3% pro-burned and crushed Bolivar flint clay, and about 17% of a binder selected from the class consisting of Sagger clay, Ball clay, and dolomite, into said body containing a mixture of equal parts of powdered alum, permanganate of potash, salicylic acid and sixteen parts of plaster of Paris, the ratio of the mixture to the total composition being approximately sixteen pounds to the ton.

6. A porous refractory liner composition consisting of a body containing about 80% preburned and crushed Missouri flint clay, about 3% pre-burned and crushed Bolivar flint clay, and about 17% Sagger clay, said body containing a dry mixture of equal parts of powdered alum, permanganate of potash, salicylic acid and sixteen parts of plaster of Paris, said mixture being in the proportion of two gallons to one ton of the total liner composition.

7. A porous refractory liner composition consisting of a body containing about 80% preburned and crushed Missouri flint clay, about 3% pre-burned and crushed Bolivar flint clay, and about 17% of a binder selected from the class consisting of Sagger clay, Ball clay, and dolomite,

said body containing a dry mixture of equal parts of powdered alum, permanganate of potash, salicylic acid and sixteen parts of plaster of Paris, said mixture being in the proportion of two gallons to one ton of the total liner composition.

DAVID MEYER. MATHIAS G. BALZER.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,204,211 Tone Nov. 7, 1916 2,458,285 Meyer Jan. 4, 1949 

2. A POROUS REFRACTORY LINER COMPOSITION CONSISTING OF A BODY OF NON-0SHRINKING HIGH FUSION BASIC FLINT CLAY AND A BINDER SELECTED FROM THE CLASS CONSISTING OF SAGGER CLAY, BALL CLAY, AND DOLOMITE, SAID BODY CONTAINING A SMALL QUANITITY OF A MIXTURE OF EQUAL PARTS OF POWDERED ALUM, PERMANGANATE OF POTASH AND SALICYLCI ACID AND SIXTEEN PARTS OF PLASTER OF PARIS, THE RATIO OF THE MIXTURE TO THE TOTAL COMPOSITION BEING APPROXIMATELY SIXTEEN POUNDS TO THE TON. 